Multiple-nozzle defined edge tool

ABSTRACT

Systems apply a material (e.g., adhesive) to an article (e.g., a component in an article of footwear) with a multiple-nozzle tool. A first nozzle of the multiple-nozzle tool is effective to provide an edge application of the material that is consistent in application of the material. A second nozzle of the multiple-nozzle tool is effective to provide a greater material coverage application than the first nozzle. The second nozzle may be implemented to apply the material at an interior area from the edge at which the first nozzle applies the material, in an exemplary aspect.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No.62/427,695, entitled “Multiple-Nozzle Defined Edge Tool,” and filed Nov.29, 2016. The entirety of the aforementioned application is incorporatedby reference herein.

TECHNICAL FIELD

Aspects provide methods and systems for applying material to an articlewith a multiple-nozzle tool.

BACKGROUND

Applying materials, such as adhesive, may be performed with a sprayingtool having a nozzle. When the material is applied unintentionallyoutside of an application area, the article to which the material isapplied may fail quality control tests because of the excessive materialapplication. Further, if the material is not applied sufficiently to aborder of the application area, the article to which the material isapplied may also fail quality control tests for an insufficient amountof applied material within the material area.

BRIEF SUMMARY

Aspects hereof provide systems and methods for applying a material(e.g., adhesive) to an article (e.g., a component in an article offootwear) with a multiple-nozzle tool. A first nozzle of themultiple-nozzle tool is effective to provide an edge application of thematerial that is consistent in application of the material. A secondnozzle of the multiple-nozzle tool is effective to provide a greatermaterial coverage application than the first nozzle. The second nozzlemay be implemented to apply the material at an interior area from theedge at which the first nozzle applies the material, in an exemplaryaspect.

DESCRIPTION OF THE DRAWINGS

The present invention is described in detail herein with reference tothe attached drawing figures, wherein:

FIG. 1 depicts an exemplary multiple-nozzle tool system, in accordancewith aspects hereof;

FIG. 2 depicts a zoomed view of the schematically depicted tool fromFIG. 1, in accordance with aspects hereof;

FIG. 3 depicts a nozzle having varied application patterns, inaccordance with aspects hereof;

FIG. 4 depicts an exemplary application pattern from the tool of FIG. 1,in accordance with aspects hereof;

FIG. 5 depicts an exemplary cross-section view of material applied tothe article surface by the first nozzle and the second nozzle of FIG. 4,in accordance with aspects hereof;

FIG. 6 depicts an exemplary cross-section view of material applied tothe article surface by the first nozzle and the second nozzle of FIG. 4,in accordance with aspects hereof;

FIG. 7 depicts a multipass material coverage from a multiple-nozzletool, in accordance with aspects hereof;

FIG. 8 depicts an application of adhesive to a footwear component by themultiple-nozzle tool of FIG. 1, in accordance with aspects hereof;

FIG. 9 depicts an alternative multiple-nozzle tool, in accordance withaspects hereof;

FIG. 10 depicts a flow diagram representing a method of applyingmaterial with a multiple-nozzle tool, in accordance with aspects hereof;and

FIGS. 11-12 depict a system using a multiple-nozzle tool with reducedtool downtime, in accordance with aspects hereof.

DETAILED DESCRIPTION

Aspects hereof provide systems and methods for applying a material(e.g., adhesive) to an article (e.g., a component in an article offootwear) with a multiple-nozzle tool. A first nozzle of themultiple-nozzle tool is effective to provide an edge application of thematerial that is consistent in application of the material. A secondnozzle of the multiple-nozzle tool is effective to provide a greatermaterial coverage application than the first nozzle. The second nozzlemay be implemented to apply the material at an interior area from theedge at which the first nozzle applies the material, in an exemplaryaspect.

In a first aspect, a multiple-nozzle tool includes a first nozzle havinga first application pattern and a second nozzle having a secondapplication pattern. The first application pattern has a smallercoverage area than the second application pattern. And the first nozzleand the second nozzle are positioned such that the first applicationpattern and the second application pattern partially overlap. Additionalaspects contemplate that the first application pattern provides a moreconsistent edge than the second application pattern, which is effectiveto provide a consistent edge application by the first nozzle. Additionalaspects contemplate that the first nozzle is positioned to effectivelyapply the material, such as adhesive, to an application edge of anarticle while the second nozzle is positioned to apply the material toan interior portion of the application area relative to the edge.

In an additional aspect, a method of applying material with amultiple-nozzle tool is contemplated. The method comprises applying amaterial from a first nozzle of the multiple-nozzle tool to an articleand contemporaneously applying the material from a second nozzle of themultiple-nozzle tool to the article. In this example, the first nozzleapplies the material at an application perimeter edge and the secondnozzle applies the material more interior on the article from theapplication perimeter edge. Additional aspects contemplate the materialapplied from the first nozzle overlapping with material applied from thesecond nozzle as the material is contemporaneously applied by the firstnozzle and the second nozzle. Additional aspects contemplate themultiple-nozzle tool traversing the article onto which the material isapplied by a movement mechanism, such as a robot, such that the firstnozzle applies material to an application perimeter while the secondnozzle applies material to an interior area of the application area. Inthis example, the first nozzle has a higher consistency at an edge ofmaterial application that is aligned with the application perimeter edgethan the second nozzle.

Additional systems, configurations, and methods will be provided hereinto further develop and expand an understanding of a multiple-nozzletool. While certain components, elements, and configurations arediscussed, it is contemplated that additional alternatives are withinthe scope of the present disclosure. For example, while two nozzles willbe discussed in connection with the multiple-nozzle tool, it iscontemplated that three or more nozzles may be implemented in aspects.Similarly, illustrative schematic components are depicted in thefigures. The components may have alternative structures and elements toaccomplish the functions as described, in exemplary aspects.

FIG. 1 depicts an exemplary multiple-nozzle tool system 100, inaccordance with aspects hereof. The system 100 is comprised of amultiple-nozzle tool (hereinafter “tool”) 102 having both a first nozzle104 and a second nozzle 106. The system 100 is further comprised of oneor more material reservoirs 110, 111 that are fluidly coupled by a line108 to the tool 102. The system 100 is further comprised of a movementmechanism 112, a computing device 114, a vision system 116, and aconveyance mechanism 118 in an exemplary aspect depicted.

The movement mechanism 112 may be any movement device, such as amultiaxial robot functional to move in one or more directions and/orrotate about one or more axes. For example, it is contemplated that themovement mechanism 112, as depicted, is able to position the tool 102 atvarious positions within three-dimensional space at various angles androtational approaches. Alternatively, the movement mechanism 112 mayoperate in the X-Y plane exclusively, in a contemplated aspect.

The computing device 114 may be comprised of a processor and memory,such as computer-readable media having instructions stored thereon that,when performed, cause one or more components (e.g., movement mechanism112, tool 102, and vision system 116) to perform one or more operations.For example, a logical coupling (e.g., wired, wireless) allows for acommunication between the computing device and one or more componentsfor both receiving and communicating information and/or instructions.The computing device may be effective for the identification of one ormore articles, such as a component used in an article of footwear (shoe,boot, sandal), from information captured by the vision system 116.Similarly, the computing device 114 may be effective to identify alocation of an article 120 as conveyed on the conveyance mechanism 118.Furthermore, the computing device 114 may be effective to coordinate theapplication of material (e.g., adhesive, paint, dye, coatings) to thearticle 120 by the tool 102. This coordination may include instructingthe movement mechanism 112 to position the first nozzle 104 and thesecond nozzle 106 relative to the article 120. The coordination may alsoinclude causing the tool to selectively and adjustably apply or dispensethe material to the article. This application may be controlled, inpart, by one or more programs detailing tool paths and applicationdetails for a particular article. Stated differently, the computingdevice 114 may have stored instructions that are used to control theapplication of material by the tool 102 onto the article 120 bycoordinating actions by one or more of the movement mechanism 112, theconveyance mechanism 118, the tool 102, and/or other components notspecifically listed.

The vision system 116 may be one or more image capturing devices, suchas a camera. The vision system may operate in the visible wavelengthspectrum, the infrared wavelength spectrum, the ultraviolet wavelengthspectrum, or other mechanisms (e.g., sonar). The vision system iseffective, when implemented in an exemplary aspect, to capture one ormore of the article 120, the tool 102, and/or the movement mechanism 112in an effort to facilitate the application of material onto the article120.

In an exemplary aspect, the vision system 116 may capture an image ofthe article 120. The captured image is communicated to the computingdevice 114 that interprets the image to identify the position,orientation, and article type. This information assists in generating anappropriate application of material and tool path for said application,in an exemplary aspect.

The material reservoir 110 (and optionally 111) provides the material tobe applied by the tool 102. For example, the reservoirs 110, 111 mayhold one or more adhesives. The reservoirs 110, 111 may be ambientpressure or pressurized to facilitate the transfer of material throughthe fluid coupling with the tool 102. It is contemplated that one ormore pumps, gravity feed, pressure differentials, and the like may beimplemented to transfer material from the reservoirs 110, 111 to thetool 102. Each nozzle of the tool 102 may be fluidly coupled to the samereservoir or to discrete reservoirs. For example, if a first type ofadhesive (e.g., a high viscosity) may be supplied to the first nozzle104 to provide a consistent edge application while a second type ofadhesive (e.g., a low viscosity) may be supplied to the second nozzle toprovide greater application coverage. As such, multiple reservoirs maybe used in connection with the tool 102. Alternatively, a commonmaterial may be supplied to all nozzles (or selected nozzles) of thetool 102 from a common reservoir. In this example, if a difference inapplication is attempted by the various nozzles of the tool 102, thenozzles themselves may be adapted to achieve differences in applicationof the common material (e.g., flow rate, pressure, application pattern,volume, and the like may be adjusted to achieve the varied application).

The conveyance mechanism 118 may be any material-movement device. Forexample, it is contemplated that the conveyance mechanism may be amultiaxis robot, a conveyor belt, a slide table, or any dynamic orstatic element effective to support and optionally move the article 120for application of material by the tool 102. In an exemplary aspect, theconveyance mechanism 118 is a conveyor having a known conveyance speed.The computing device 114 coordinates the movement of the tool 102 by themovement mechanism 112, such that the application of material by thetool 102 occurs while the article 120 is conveyed by the conveyancemechanism 118, in an exemplary aspect.

As can be appreciated, the items, elements, components, and/or devicesdepicted in FIG. 1 are exemplary in nature and are not limiting.Further, the relative positioning, size, and numbers are also notintended to be limiting, but instead exemplary in nature.

FIG. 2 depicts a zoomed view of the schematically depicted tool 102 fromFIG. 1, in accordance with aspects hereof. As depicted, the first nozzle104 and the second nozzle 106 are physically coupled while independentlymoveable. For example, the movement mechanism 112 may position the firstnozzle 104 and the second nozzle 106 at various macro positionsconcurrently, but each of the nozzles may further move independentlyfrom one another based on rotations at respective coupling points, asdepicted by arrows of motion at couplings of the individual nozzles tothe greater tool 102.

The first nozzle 104 is depicted as having a coupling joint 202 allowingfor rotational movement about both a Y and a Z-axis. Similarly, acoupling joint 204 associated with the second nozzle 106 allows for avariety of degrees of motion. This additional movement may allow one ofthe nozzles (e.g., the first nozzle 104) to apply material to a surfaceoff of horizontal (e.g., a side wall surface of a sole unit) while anadditional nozzle (e.g., second nozzle 106) applies material to a morehorizontal surface (e.g., footbed portion of the sole unit). Therefore,while used in concert, the tool 102 may adjust an application anglebetween the plurality of nozzles to effective apply material to anarticle.

FIG. 3 depicts a nozzle 300 having varied application patterns, inaccordance with aspects hereof. The nozzle 300 is representative of anozzle that may be included in the tool 102 of FIG. 1, in an exemplaryaspect. The nozzle 300 may dynamically or statically adjust theapplication pattern to vary a distribution area of application. Forexample, an article surface 316 that is a distance 314 from the nozzle300 is depicted. Based on the distance 314, a varied coverage isachieved on the article surface 316. For example, a coverage 312 isachieved with an angle 306, a coverage of 310 is achieved with an angle304, and a coverage 308 is achieved with an angle 302. The variousangles are depicted in a two-dimensional manner, but it is contemplatedthat the resulting application pattern may take on any footprint, suchas a linear fan, a conical structure, or a rectilinear structure, whenviewed from the nozzle toward the article surface 316, in an exemplaryaspect. As such, it is contemplated that the application pattern of anozzle may be adjusted prior to applying a material or may be adjustedwhile the material is applied to the article. The adjustment of theapplication pattern during application of the material allows for avaried application of material as a continuous operation and as a resultallows for a shorter cycle time with less waste of material, in anexemplary aspect.

The application patterns and angles depicted in FIG. 3 are exemplary innature and are not limiting as to scope. Instead, they are demonstrativeas to potential applications of a nozzle for a varied applicationpattern. It is also contemplated that an output port of the nozzle maybe replaced to achieve a desired application pattern. Further, it iscontemplated that a computing device (e.g., computing device 114 ofFIG. 1) may control the application pattern by a nozzle. The computingdevice may have one or more predetermined application patterns based ontool paths to achieve an effective coverage of material applicationwhile limiting over application, in an exemplary aspect.

FIG. 4 depicts exemplary application patterns from the tool 102, inaccordance with aspects hereof. The first nozzle 104 has an output port406 and the second nozzle 106 has an output port 408. Material, such asan adhesive, paint, colorant, primer, durable water repellant, and othersurface treatments, is expelled from the output port toward an articlesurface 416. As previously discussed, the material may be expelled underpressure by a pump motor, pressurized gas, gravity, and the like. In anexemplary aspect, the material is an adhesive that is sprayed from thenozzles either by pressurized gas or a pump. The application pattern ofthe material as it contacts the article surface 416 is determined by therespective nozzles and potentially other controlled variables (e.g.,material volume, pressure, distance, material characteristics).

As presented previously, the production of an article of footwearrelies, in part, on materials being applied to articles/components. Forexample, a sole (e.g., midsole and/or outsole) may be affixed to alasted upper (e.g., the foot-surrounding material of a shoe asmaintained on a tooling known as a cobbler's last) by an adhesiveapplied to one of the bottom of the lasted upper and/or the non-groundfacing surface of the sole. An intersection is formed at a transitionfrom the upper to the sole when joined, which is referred to as abiteline. Adhesive that extends above the biteline may be visible on theupper as it is not obscured by the sole. If adhesive does not extend allof the way to the biteline and instead falls below the biteline, thesole could separate from the upper at the biteline causing a failure. Asa result, when manufacturing an article of footwear, the application ofthe adhesive up to, but not extending beyond, the biteline allows for anacceptable article. When automating the application of a material by anozzle, control of the application of the material is related to theexample provided above about adhesive to the biteline. A level ofconsistency (e.g., precision and anticipated deposition of material) atthe edge of material application is beneficial to minimize creation ofunacceptable articles by ensuring appropriate coverage of the materialat intended locations.

The first nozzle 104 outputs material in a first application pattern 402that has a coverage area represented by area 410. For discussionpurposes, the cross-sectional shape of the application patterns iscircular in nature, but it could be any shape, as previously discussed.Therefore, a coverage area provided by the first application pattern 402when the cross-sectional shape is circular is the formula fordetermining circular area (i.e., area=0.25πD², where “D” is the distancerepresented by numeral 410 in this example). Therefore, the coveragearea of the first application pattern 402 is less than the coverage of asecond application pattern 404 from the second nozzle 106 that has asurface contact length represented by a numeral 412 at the articlesurface 416.

The first nozzle 104 may output material, such as adhesive, within arange of 0.05 gram per second (i.e., 0.05 g/sec) to 0.3 g/sec whileachieving a spray width of 2 millimeters (mm) to 15 mm and a depth(e.g., thickness) of material application in the about 10 to 60micrometer range (plus or minus 10%), in an exemplary aspect. The secondnozzle 106 may output material, such as adhesive, within a range of 0.1g/sec to 0.5 g/sec while achieving a spray width of 5 mm to 25 mm and adepth (e.g., thickness) of material application in the 10 to 60micrometer range, in an exemplary aspect. It is contemplated that a flowrate, spray width (e.g., diameter), and/or application depth may beindependently changed from those values provided to achieve aspectshereof.

There is an overlap area 414 of material from the first applicationpattern 402 and from the second application pattern 404. Having theoverlap area 414 compensates for lack of consistency at an applicationedge caused by the second application pattern 404. If insufficient orinconsistent material is applied at an area (e.g., edge of anapplication pattern), the resulting article may not meet qualitystandards. Therefore, in an exemplary aspect, the second applicationpattern 404 overlaps with the first application pattern 402 to ensuresufficient application of material at an area proximate the boundary ofthe second application pattern 404. A cross-sectional perspective of thematerial application highlights a distinction between the consistentapplication edge of the first nozzle 104 and the greater surfacecoverage with less consistent edge application of the second nozzle 106,as seen in exemplary FIG. 5 hereinafter.

FIG. 5 depicts an exemplary cross-section view 500 of material appliedto the article surface 416 by the first nozzle 104 and the second nozzle106 of FIG. 4, in accordance with aspects hereof. A first material isapplied by the first nozzle 104 in the area defined by the numeral 410and a second material is applied by the second nozzle 106 in the areadefined by the numeral 412. The first application pattern forms anapplication edge 506 that is relatively consistent and precise. Thesecond application pattern forms application edges 508, 510 that aremore graduated and therefore less consistent from a material volumeapplication perspective. For example, the application edge 508 isdepicted as tapering in material application thickness. The closer tothe edge of material application, the less material that is deposited.This gradient of application can result in an insufficient amount ofmaterial application for quality control purposes. As a result, at theapplication edge 510 of the second application pattern, the firstapplication overlaps coverage to ensure a sufficient amount of materialis deposited in an area demarcated by the numeral 414.

The overlap area therefore is formed from material applied by the firstnozzle 104 and material applied by the second nozzle 106 from FIG. 4, inan exemplary aspect. This overlap compensates for the lack of consistentmaterial application at the application edge 510 of the secondapplication pattern. In exemplary aspects, the second applicationpattern deposits material over a greater area than the first applicationpattern during a comparable movement and application time. A result ofthe greater coverage area of the second application pattern may, in anexemplary aspect depicted in FIG. 5, be a reduction in application edgeconsistency that is therefore compensated for with an overlapping areawith another application pattern or subsequent overlap with the sameapplication pattern as will be discussed in FIG. 7 hereinafter.

A depth 504 is achieved in the area 412. A depth similar to depth 504 isalso achieved in the area 410, in an exemplary aspect. It is understoodthat the depth of the area 412 and 410 may be similar or different inaspects hereof. Similarly, it is contemplated that the depth 504 may bewithin a range of 10 to 60 micrometers to achieve acceptable qualitymetrics in footwear construction; however, it is contemplated as beinggreater or lesser in thickness in alternative aspects. Further, in anoverlap area, such as area 414, it is contemplated that the combinationof materials from the first nozzle and from the second nozzle alsoresults in a material thickness within the range of 10 to 60micrometers. This exemplary range of adhesive thickness allows fortraditionally used materials in the footwear manufacturing industry toachieve a sufficient bond for quality control purposes.

FIG. 6 depicts an exemplary cross-section view 600 of material appliedto the article surface 416 by the first nozzle 104 and the second nozzle106 of FIG. 4, in accordance with aspects hereof. As distinguished fromFIG. 5, characteristics of the material smooth out and normalizetransitions between application patterns. For example, the material 602deposited by the first nozzle 104 and the material 604 deposited by thesecond nozzle 106 of FIG. 4 overlap and form a converged portion 606.The height transition from material 602 to material 604 is not aspronounced as in the depiction of FIG. 5 as a result of materialinteractions, such as surface tension and material attraction as thematerials interact at the converged portion 606. In this example, theconverged portion 606 and the boundary portion of material 604 may havea smaller quantity in some portions than other portions, but the amountof material overlap to form the converged portion 606 is sufficient, inan exemplary aspect, to achieve quality standards.

FIG. 7 depicts a multipass material coverage 700 from a multiple-nozzletool, in accordance with aspects hereof. The material 724 is applied intwo passes: a first pass 720 and a second pass 722. As can be seen, themultiple-nozzle tool applies material such that a first nozzle applies afirst material 702, 710 to a perimeter boundary forming boundary edges704 and 712, respectively. The boundary edges provide a sufficientdegree of consistency of material application at exterior perimeters. Aspreviously discussed, the first nozzle 104 of FIG. 4 may be implementedto apply the material 702 and 710.

A second material 706 in the first pass 720 and a second material 714 inthe second pass 722 provide a greater coverage area of material than thefirst material 702, 710 applications. The second nozzle 106 from FIG. 4may be effective for applying the second material 706, 714. The firstpass 720 and the second pass 722 cause an overlap 718 of second material706, 714. The overlap 718 of second material, in an exemplary aspect,compensates for a more inconsistent boundary edge than provided by thefirst nozzle 104, in an exemplary aspect. As the second material isapplied to an internal area defined by an exterior perimeter of theboundary edges 704, 712, the lower consistency in application amountrelative to the first material does not have as much of an impact onquality standards, in an exemplary aspect. For example, as the secondmaterial may be applied to a central area of a sole as opposed toproximate where a biteline is defined, there is less opportunity fortearing or peeling to cause a separation of parts if the material is anadhesive at the central area as opposed to the biteline/intersection ofdisparate components.

Further, in the first pass 720 and the second pass 722, an overlapbetween the first material 702, 710 and the second material 706, 714,respectively, create overlap material 708, 716, also respectively. Theseoverlaps compensate for variability in boundary edges that may occurwith the application of the second material by a nozzle adapted to applyover a greater area with less consistency than a nozzle that applies amore precise, limited material, such as the first nozzle. Stateddifferently, by creating an overlap portion of the second applicationpatterns, which provides a greater coverage but less precision than thefirst application pattern, the overlapping portions of the secondapplication patterns compensate for variability in the boundary edges ofthe second application pattern to ensure sufficient material is applied.

FIG. 8 depicts an application 800 of adhesive to a footwear component802 (e.g., sole) by the multiple-nozzle tool 102, in accordance withaspects hereof. Similarly numbered elements of FIG. 8 are captured inthe previously discussed FIGS. 1-7. For example, the tool 102 aspreviously described includes the first nozzle 104 having the firstapplication pattern and the second nozzle 106 having the secondapplication pattern, wherein the second application pattern provides agreater coverage area than the first application pattern. Additionally,the first application pattern provides a more controlled, precise, andconsistently applied material at the boundary edges that ensuressufficient and appropriate material application at an applicationboundary/edge for quality control, in an exemplary aspect.

The footwear component 802 is depicted as a sole, but it can be anycomponent in an article of footwear, such as a lasted upper. Thefootwear component 802 is depicted as having a perimeter 804 at which anapplied material is intended to be applied, but not to extend past. Forexample, the perimeter 804 may be a bonding edge, such as a bitelinewhere a sole and an upper intersect. If the material extends beyond theperimeter 804, the material may extend into a visible portion of thefootwear that detracts from an intended visual appearance. Similarly, ifthe material fails to extend to the perimeter 804, the sole and a bondedupper may be prone to separation at the intersection. As such, aconsistent and precise application of material up to the perimeter 804is attempted by use of the multiple-nozzle tool 102 and the first nozzle104.

The material application depicted in FIG. 8 is the first pass 720 fromFIG. 7 prior to the application of the second pass 722. As such, thefirst material 702 is applied such that the boundary edge 704corresponds with the perimeter 804. Because of the consistentapplication of material, such as an adhesive, by the first nozzle 104, ahigh tolerance of material application having the boundary edge 704aligned with the perimeter 804 is possible. The second material 706covers a greater surface area of the footwear component 802 than thefirst material 702. As the second material 706 is more interior from theperimeter 804 than the first material 702, less precision in exchangefor the greater coverage area is allowed in an exemplary aspect, as thematerial can still be maintained at the perimeter 804 by the firstnozzle 104 while achieving application coverage in the interior of theperimeter 804 by the second nozzle 106. An interior area is, in anexemplary aspect, an area that does not include a perimeter edgeintended to have a high consistency application of material. Withrespect to footwear, an interior area may be the bottom surface of alasted upper up to an area covered by a more precisely applied material.

The area within the perimeter 804 has material applied by themultiple-nozzle tool 102. The multiple-nozzle tool 102 may follow arobot tool path that controls the location of material application toensure application up to the perimeter 804 and providing sufficientoverlap between material portions and passes. The tool path is depictedby an arrow 806 as the multiple-nozzle tool 102 extends from a medialside of the footwear component 802 towards a toe end before eventuallyheading in a heel-ward direction along the lateral side of the footwearcomponent 802, in this exemplary aspect. This loop-like tool path allowsfor the second nozzle 106 to remain more proximate the interior and thefirst nozzle 104 to remain more proximate the perimeter 804 whileapplying material on the article of footwear component 802, in thisexemplary aspect. When completed, the cross-section of FIG. 7 depicts anexemplary material application across an article of footwear component,such as the article of footwear component 802 of FIG. 8.

FIG. 9 depicts an alternative multiple-nozzle tool 902, in accordancewith aspects hereof. A first nozzle 904 is coupled by a coupling element914 with a second nozzle 906. The first nozzle 904 has an output port907 providing a first application pattern 910 of a material. The secondnozzle 906 has an output port 908 providing a second application pattern912 of a material. The first application pattern 910 is more controlled,precise, and consistent in material application at boundary edges thanthe second application pattern 912. Conversely, the second applicationpattern 912 provides greater surface area coverage than the firstapplication pattern 910. Therefore, as discussed with respect to themultiple-nozzle tool 102 previously, the first nozzle is adapted toapply material, such as adhesive, proximate a perimeter and the secondnozzle is adapted to apply material over a larger surface area with lessedge boundary precision.

It is contemplated that an angle between the first nozzle 904 and thesecond nozzle 906 as maintained by the coupling element 914 isconfigured such that the first application pattern 910 and the secondapplication pattern 912 overlap at a component's (e.g., sole) surface ata known distance therefrom to ensure sufficient material application.However, in an alternative aspect, pressure, nozzle angle, volume,approach angle, and the like may all be varied dynamically during theapplication of the material by one or more instructions from a computingdevice. Therefore, a static configuration is not limiting.

FIG. 10 depicts a flow diagram representing a method 1000 of applyingmaterial with a multiple-nozzle tool, in accordance with aspects hereof.At a block 1002, material is applied to an article from amultiple-nozzle tool, such as the multiple-nozzle tool 102 of FIG. 1 orfrom the multiple-nozzle tool 902 of FIG. 9. The material may be anymaterial, such as a colorant, adhesive, primer, or surface treatment.Further, the material may be liquid, gel, particulate, or the like. Forexample, some materials may be powder based, some may be liquid based,and some may be viscous solutions. The application of the material maybe controlled by a computing device in connection with one or morecomponents, such as a movement mechanism (e.g., robot), a vision system,material pressurization/pump components, and the like.

At a block 1004, the method continues contemporaneously applying thematerial from a second nozzle of the multiple-nozzle tool to thearticle. The first nozzle applies the material at an applicationperimeter edge and the second nozzle applies the material more interioron the article from the application perimeter edge. Contemporaneousapplication of the material contemplated both the first and secondnozzles applying the material at a common time to prevent, in anexemplary aspect, a multiple-pass operation of discrete tools. Instead,a common tool movement can position both the first nozzle and the secondnozzle appropriately for application of material. This may reduce cycletime for applying the material as the number of independent movementsmay be reduced, in an exemplary aspect. As used herein, an interiorportion of an article is a location on the article that is distal from aperimeter at which consistency (e.g., consistent volume of material,precise application of material) is intended.

As the first nozzle is intended to apply, in this example, material atan edge boundary proximate an application perimeter, the first nozzleapplies a smaller volume of material over a smaller area than the secondnozzle. Stated differently, the second nozzle applies a greater volumeof material in a given time than the first nozzle that iscontemporaneously applying material, in an exemplary aspect.

As previously discussed with respect to FIG. 7, it is contemplated thatthe method may also include moving the multiple-nozzle tool whileapplying the material such that the material applied from the secondnozzle at a first time overlaps with the material applied by the secondnozzle at a second time. This creates the overlap 718 of FIG. 7.Additionally, this allows for the first nozzle to continue to applymaterial along a perimeter and the second nozzle to apply material at aninterior portion while still providing the material across the wholeintended article, in an exemplary aspect.

While the aspects illustrated focus on two nozzles, it is contemplatedthat any number of multiple nozzles may be implemented. For example, athree, four, or five-nozzle system may be used. Each of the nozzles mayhave different application patterns depending on the article andintended application. Therefore, it is contemplated that a consistentapplication pattern may be used within an interior of the article and alarge surface area application pattern may be used proximate aperimeter, in an exemplary aspect.

FIGS. 11 and 12 depict a multiple-nozzle tool system 1100, in accordancewith aspects hereof. The multiple-nozzle tool 102 is depicted as beingmoveable by the movement mechanism 112, in this depiction. Efficienciesof the system may be achieved through the independently moveableconveyance mechanisms 1102, 1104 capable of retrieving, positioning, anddelivering one or more parts relative to the multiple-nozzle tool 102.For example, the retrieval and delivery portions of a manufacturingcycle may not utilize the multiple-nozzle tool 102, causing that tool toremain idle during those portions. As such, a first part 1106 in FIG. 11is positioned by the conveyance mechanism 1102 for the multiple-nozzletool 102 to apply material (e.g., adhesive) thereto while a second part1108 is depicted as being retrieved by the conveyance mechanism 1104. Asthen depicted in FIG. 12, the first part 1106 is delivered following theapplication of material by the multiple-nozzle tool 102 and the secondpart 1108 has been retrieved and is receiving material from themultiple-nozzle tool 102. This reciprocating action reduces cycle timeand increases the return on investment for the multiple-nozzle tool 102as it is applying material a greater portion of time rather than sittingidle as parts are retrieved and/or delivered.

It is contemplated based on the system 1100 of FIGS. 11 and 12 that amethod of manufacturing may be implemented. A first step may includeretrieving a first part with a first conveyance mechanism. The firstpart is positioned by the first conveyance mechanism in a locationsuitable for a multiple-nozzle tool to apply material at definedlocations with appropriate spray characteristics. Once located, themultiple-nozzle tool applies a material, such as an adhesive, to thefirst part at specified locations with at least a first and a secondnozzle working in cooperation to efficiently and precisely apply thematerial along a defined boundary and interior portion. Following theapplication of material to the first part, the first part is deliveredfrom the multiple-nozzle tool by the first conveyance mechanism.

A second conveyance mechanism retrieves a second part prior to thesecond part being delivered by the first conveyance mechanism. Forexample, while the first part is having material applied thereon by themultiple-nozzle tool, the second conveyance mechanism may retrieve thesecond part. Following the application of material to the first part,the multiple-nozzle tool may then reposition to apply material to thesecond part. During the application of material to the second part, thefirst part may be delivered by the first conveyance mechanism, in anexemplary aspect.

While one or more multiple-nozzle tools are depicted in connection withFIGS. 11 and 12, it is contemplated that the arrangement andconfigurations provided may be implemented with any tool or process. Forexample, it is contemplated that a sewing machine, a printer, a painter,a cutting machine, an assembly apparatus, and the like may beimplemented in connection with the depicted conveyance mechanismarrangements to achieve manufacturing efficiencies, in exemplaryaspects. For example, instead of a multiple-nozzle tool performing anoperation as described in connection with FIGS. 11 and 12, it iscontemplated that a material coating tool (e.g., a paint sprayer, an inksprayer, a durable water repellant applicator, or the like) may applyone or more materials to portions of article of footwear in a mannersimilarly depicted in FIGS. 11 and 12. Additionally it is contemplatedthat alternative tool paths may be implemented in connection with FIGS.11 and 12. For example, depending on an operation to be performed, adifferent tool path used by the tool performing the operation may beimplemented to achieve the operation.

From the foregoing, it will be seen that this invention is one welladapted to attain all the ends and objects hereinabove set forthtogether with other advantages which are obvious and which are inherentto the structure.

It will be understood that certain features and subcombinations are ofutility and may be employed without reference to other features andsubcombinations. This is contemplated by and is within the scope of theclaims.

While specific elements and steps are discussed in connection to oneanother, it is understood that any element and/or steps provided hereinare contemplated as being combinable with any other elements and/orsteps regardless of explicit provision of the same while still beingwithin the scope provided herein. Since many possible embodiments may bemade of the disclosure without departing from the scope thereof, it isto be understood that all matter herein set forth or shown in theaccompanying drawings is to be interpreted as illustrative and not in alimiting sense.

1. A multiple-nozzle tool, comprising: a first nozzle having a firstapplication pattern; and a second nozzle having a second applicationpattern, the first application pattern has a smaller coverage area thanthe second application pattern, and the first nozzle and the secondnozzle are positioned such that the first application pattern and thesecond application pattern partially overlap.
 2. The multiple-nozzletool of claim 1, wherein the first nozzle is an edge applicator and thesecond nozzle is an interior applicator, wherein the first nozzleapplies a smaller volume of material than the second nozzle.
 3. Themultiple-nozzle tool of claim 1, wherein the first nozzle and the secondnozzle are coupled to a common movement mechanism able to move the firstnozzle and the second nozzle in at least two directions.
 4. Themultiple-nozzle tool of claim 1 further comprising a computing device,wherein the computing device controls the first application pattern andthe second application pattern.
 5. The multiple-nozzle tool of claim 4further comprising a vision system, the vision system is logicallycoupled with the computing device.
 6. The multiple-nozzle tool of claim1, wherein the first nozzle applies material to the article having adepth in a range of about 10 micrometers to about 60 micrometers.
 7. Themultiple-nozzle tool of claim 1, wherein the first nozzle isindependently operable from the second nozzle to apply a material. 8.The multiple-nozzle tool of claim 1, wherein the first nozzle and thesecond nozzle are fluidly coupled to a material dispensing deviceeffective to dispense a material applied by the first nozzle and thesecond nozzle.
 9. The multiple-nozzle tool of claim 1, wherein the firstnozzle is fluidly coupled to a first material reservoir and the secondnozzle is fluidly coupled to a second material reservoir.
 10. Themultiple-nozzle tool of claim 1, wherein the first nozzle distributes asmaller quantity of material than the second nozzle during a comparableapplication time, wherein the first nozzle distributes material in arange of 0.1 grams/second to 0.3 grams/second.
 11. The multiple-nozzletool of claim 1, wherein the first nozzle and the second nozzle applymaterial contemporaneously.
 12. The multiple-nozzle tool of claim 1,wherein the first nozzle is positioned at a perimeter of an article ontowhich the first application pattern is directed and the second nozzle ispositioned at a more interior position of the article onto which thesecond application pattern is directed.
 13. The multiple-nozzle tool ofclaim 1, wherein the first nozzle and the second nozzle are positionedequidistant from an article.
 14. A method of applying material with amultiple-nozzle tool, the method comprising: applying the material froma first nozzle of the multiple-nozzle tool to an article; andcontemporaneously applying the material from a second nozzle of themultiple-nozzle tool to the article, wherein the first nozzle appliesthe material at an application perimeter edge and the second nozzleapplies the material more interior on the article from the applicationperimeter edge.
 15. The method of claim 14, wherein the article is acomponent in an article of footwear.
 16. The method of claim 14, whereinthe material is an adhesive.
 17. The method of claim 14 furthercomprising capturing the article with a vision system, wherein thevision system is logically coupled with a computing device and thecomputing device is logically coupled with a movement mechanismeffective to move the multiple-nozzle tool.
 18. The method of claim 14,wherein the applying the material from the first nozzle applies lessvolume of the material during a same time as applying the material fromthe second nozzle.
 19. The method of claim 14 further comprising:overlapping the material applied from the first nozzle with the materialapplied from the second nozzle; and moving the multiple-nozzle toolwhile applying the material such that the material applied from thesecond nozzle at a first time overlaps with the material applied by thesecond nozzle at a second time.
 20. The method of claim 14, wherein thefirst nozzle travels a greater distance than the second nozzle whileapplying the material to the article.